Kia Sportage: Delivery Pipe: Repair procedures

Kia Sportage Service & Repair Manual (3rd Generation, SL; 2011-2016) / Engine Control / Fuel System / Fuel Delivery System / Delivery Pipe: Repair procedures

Removal

In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.

1.	Turn the ignition switch OFF and disconnect the battery negative (-) cable.

Release the residual pressure in fuel line (Refer to the Fuel Delivery System - Repair Procedures - "Release Residual Pressure in Fuel Line").

When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of “Release Residual Pressure in Fuel Line” work.

3.	Remove the intake manifold (Refer to "Intake And Exhaust System" in EM group).

4.	Disconnect the injector connectors (A) and the rail pressure sensor connector (B).

5.	Remove the high pressure fuel pipe (C).

6.	Remove the installation bolt (D), and then remove the delivery pipe and injector assembly from the engine.

Installation

•	Install the component with the specified torques.

•	Apply engine oil to the injector O-ring.

•	Do not use already used injector O-ring again.

•	Do not reuse the bolts.

•	When insert the injector, be careful not to damage the injector tip.

•	Use proper tooling for change of combustion seal. Take proper precautions not to damage surface during assembly or disassembly.

•	Avoid dropping the fuel pipe (including injectors) or bumping it into any hard objects sincedamage to the internal components may occur. If necessary, visually inspect and confirmproper operation with performance tests prior to reuse.

•	Before installing the injector into the cylinder head, clean the injector hole and avoidcontaminants from entering inside the injector hole. When installing the injector, avoid bumpingthe injector tip into any of the surrounding components since the tip may become damagedfrom the impact.

•	When fastening the three fuel delivery pipemounting bolts, fully hand-tighten first, andthen tighten in the proper sequence ( > > ) in several cycles up tothe specified torque. The delivery pipeshould move less than 1/8 inch (approx.3mm), whenever each bolt is tightened.

Installation is reverse of removal.

Delivery pipe installation bolt:

18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

High pressure fuel pipe installation nut:

26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)

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